Wire-wrap connector assemblies in which connector blocks are loosely held for wire-wrapping and thereafter tightened



1970 G. R. HUMPHREY, JR, ET AL Jam. 13, 3,489,954

WIRE-WRAP CONNECTOR ASSEMBLIES IN WHICH CONNECTOR BLOCKS ARE LOOSELY HELD FOR WIRE-WRAPPING AND THEREAFTER TIGHTENED 2 Sheets-Sheet 1 ill illll HI! Filed 001' 22, 1965 6 2 r .A I w .w a o o o 1/ m w m M o o o m m O O O Q w 0 0 O O 1 GERALD R HUMPHREKJK CHARLES /V. MAZZA INVENTORS ATTORNEYS Jan, 13, 1970 G. R..HUMPHREY, JR ET AL 3,489,954

WIRE-WRAP CONNECTOR ASSEMBLIES IN WHICH CONNECTOR BLOCKS ARE LOOSELY HELD FOR WIRE-WRAPPING AND THEREAFTER TIGHTENED Filed 001.. 22, 1965 2 Sheets-Sheet 2 J/G PLATE WIRE WRAP MACH/IVE LUCA 70/? Pl/VS NE/VTORS GERALD R. HUMPHREY Jr. CHARLES /v. MAZZA United States Patent U.s. c1. 317 1o1 12 Claims ABSTRACT OF THE DISCLOSURE The specification discloses the combination of connector blocks with wire wrapping' and mounting means that can hold the connector blocks loosely while they are mated with a wire-wrap machine, and then tightly for assembly in a system. i

Thisinventionjrelates to electrical connectors having wire-wrap terminals and in particular to configurations of a, plurality of such connectors in a single assembly adapted for automatic wire-wrapping with provision for precision locating of the individual connector units.

'One of the modern methods or making fast reliable electrical wire connections is by wrapping the end of the wiretightly around a terminal of rectangular cross section. The s harp corners of the terminal bite into the wire providing electrical and mechanical connection. This method has been-adapted to mass production by machines which can ,be set up to wrap wires. in a predetermined manner on a large plurality of terminals in connectors, terminal blocks, or circuit boards. One of the problems encountered is the high precision positioning required to enable the wirewrap machines to reliably engage a plurality of wires to a plurality of terminals simultaneously.

When the terminalsare all secured. in a single base element, then ,position accuracy is achieved by accuracy in the manufacture plus accurate jigging of the. base element into position in the wirewrap machine. Frequently however a connectoris a small unit and it is desirable to operate on aplurality of these units simultaneously. This multiplies the positioning problem manifold. 1

One reason for working with small units is that they.

can be manufactured identically for various applications using small or large numbers of such units. A second reason is ease of maintenance. In making repairs a smaller unit can be handled, replaced, or repaired as necessary.

The present invention proposes an assembly of connector units supported together in a framework. The framework is designed to loosely support the connectors, so that they may be keyed accurately into position for wire-wrapping, and then to tightly support the connectors in an assembled equipment. Each connector unit contains precisely located keying means for mating with keying means in a wire-wrapping jig. The connectors are .first assembled and supported in a framework as they will be in the end equipment. They are then individually keyed into precise locations by jigs associated with a wire-wrap machine. All wires are connected by wire-wrap in the machine. Then the framework carrying the connectors and connecting wires is tightened to rigidly clamp the connectors as .an assembly. The assembly is fastened into the end equipment by fastening the framework to the equipment housing. Thus it is an object of the invention to provide a unitized assembly adapted for mass wirewrapping.

3,489,954 Patented Jan. 13, 1970 It is a further object of the invention to' provide electrical equipment containing an assembly of Wire-Wrapped units.

It is a further object of the invention to provide a wirewrap connector including locating means for positioning in a Wire-wrap machine.

It is still a further object of the invention to provide a method of wire-wrapping a plurality of units in a single assembly.

Further objects and features of the present invention will become apparent upon reading the following Specification together with the drawings in which:

FIG. 1 is a projection of a wire-wrap connector block.

FIG. 2 is a cross-section of the block of FIG. 1 connected by a frame member to a second connector block.

FIG. 3 is a projection of an electronic equipment enclosure with a number of connector blocks mounted in a frame fastened to the equipment.

FIG. 4 is a projection of a connector block with a plug-in circuit module.

FIGURE 5 is a simplified pictorial representation of a connector block assembly in exploded mated relationship with a jig plate of a wire-wrap machine.

While the present invention applies to terminal boards, circuit boards, and the like, it is described herein in particular relation to connector blocks. A connector block 10 with wire-wrap terminals 11 is illustrated in FIG. 1.

A sixteen by seventeen array of terminals 11 is shown and has been used in practice, however the number of terminals in each block is not critical and is not part of the invention. The protruding portions of terminals 11 are generally about /2. inch long with a rectangular cross-' section of about .020 by .030 inch. These dimensions are not critical and will vary with the wire size for different applications. The terminals are crimped, pressed, cement-' cd, or otherwise secured in the block precisely positioned. For purposes of the invention it is preferred that the positioning of the pins be held to a tolerance in the range of plus or minus .002 to .006 inch. Commonly for automatic .wire-wrapping, the overall position tolerance must be held to .012 inch of center or better.

The block itself can be made of any of the materials commonly used for electrical terminal boards or the like. For example, phenolic or glass fiber materials or any of various other rigid materials providing electrical insulation of the pins one from another are suitable. Each block is made with a tongue 12 extending'the length of block 10. The location of the apertures is not critical but they must be precisely located with respect to locating pins that will be used to position them as will be seen below. Other conventional locating means can readily be used.

Frame members 15 which are suitably extruded from aluminum have channels 17 and 18 extending their length adapted to receive tongues 12 and 13. Channels 17 and 18 are designed to hold tongues 12 and 13 loosely.

Thus the channels are large enough in one embodiment .19. These holes are used for screws to hold an entire 3 assembly of blocks together as described in relation to FIG. 3.

FIG. 3 shows a plurality of blocks 10 held together by frame members 15, end frame members 20 and angle clamping members which are in the nature of cross members 21 and 22 in an assembly 23. Frame members 20 are suitably identical to frame members 15. If desired, frame members 20 can be made with only one of channels 17, 18. Assembly 23 is mounted by means of screws 25 in electronic equipment 26. Screws 27 screw into holes 19 as shown in FIG. 2 to fasten angle members 21 and 22 to frame members and 20. Frame members 15 and 20. Frame members 15 and are made slightly shorter than the added length of blocks 10 to be engaged thereby. On first assembly angle members 21 and 22 are only loosely screwed to the frame members in order to leave the blocks loose for independent movement. For wirewrapping, the angle members are fastened to a jig plate associated with the wire-wrap machine as shown in FIGURE 5. Pins in the jig plate engage apertures 16 in each of blocks 10, precisely positioning the blocks on the jig plate. Each of the blocks is independently free for this precise positioning due to the clearance between tongues 12, 13 and channels 17, 18. For example with the .015 inch clearance stated above, each block can be shifted by 12015 inch independently of the other blocks.

With the particular embodiment described it has been found possible to obtain position accuracy so that pins 11 are located within .010 inch of predetermined positions for the wire-wrapping machine. Fastening angle members 21 and 22 tightly to the jig plate holds blocks 10 tightly against the locating pin in the jig plate so that there is no undesired movement of the blocks during wire-wrapping. After the wire-wrapping is completed angle members 21 and 22 are unfastened from the jig plate and are fastened to the apparatus in which the assembly is to be utilized. This fastening is done, for example, by screws or bolts 25. Screws 27 are tightened to pull the angle members 21 and 22 tightly against blocks 10.

Frame members 15 and 20 are cut slightly shorter than the added length of blocks 10 between any two of the frame members. Due to the short length of the frame members, angle members 21 and 22 come up tightly against blocks 10 upon tightening of screws 27 until blocks 10 are rigidly clamped in the assembly. It will be seen that any number of blocks 10 or similar units can be arranged in a frame assembly of the type described and retained therein both for wire-wrapping with allowance for precise location of the individual units and for mounting into the end apparatus with all independent freedom eliminated by tightening a few screws.

Connector blocks 10 can take a number of useful forms and may include a number of receptacle apertures as illustrated in FIG. 2 adapted to receive the pins of a connector plug 31 as illustrated in FIG. 3 or for the connection of plug-in circuit modules 32 or other connections. Referring again to FIG. 2 it will be seen that receptacle apertures 30 provide for connection of the pins of plug-in units to wire-wrapping terminals 11 inside connector blocks 10. FIG. 2 shows each of apertures 30 connected to two of the wire-wrap terminals 11. Block 10 can also be made so that each of apertures 30 provides for connection to only one wire-wrap terminal 11 or to any number of wire-wrap terminals.

FIG. 4 depicts one of connector blocks 10 in which one circuit module card 32 is plugged into one row of receptacle apertures. Pins (not shown) extending from the edge of card 32 are plugged into the receptacle apertures 30 for making electrical connections to the card. The card may carry electrical components, printed circuits, and/or monolithic circuits 33.

Connector blocks 10 assembled in a quantity, for example 12 blocks as illustrated in FIG. 3, can be mounted 4 in a piece of electronic equipment 26 with each block 10 being used variously as for connection of a plug 31 with a cable for connection to other assemblies or equipment or for the connection of module cards 32 containing components such as resistors, capacitors, printed and monolithic circuits.

While the invention has been described in relation to specific embodiments, various modifications thereof will be apparent to those skilled in the art and it is intended to cover the invention broadly within the spirit and scope of the appended claims.

What is claimed is:

1. An assembly of wire-wrap modules comprising:

(a) a plurality of rectangular connector blocks having mounting guides on two opposite edges;

(b) a plurality of wire-wrap terminals extending from one surface of each of said blocks;

(c) locating means on each of said blocks for mating with locating means on the jig of a wire-wrap machine;

(d) at least two elongated mounting members for receiving and loosely engaging the mounting guides of a plurality of said blocks, aligned in a row etween them, the length of each mounting member being slightly less than the length of said row of blocks;

(e) means to engage the ends of said frame members loosely, while leaving each of said blocks free for limited independent movement in direction parallel to said one surface thereof for mating said locating means of each block with locating means on the jig of a wire wrap machine; and

(f) means to tighten said means to engage on said ends compressively against said row of blocks between said mounting members for securing said blocks rigidly into position. I

2. An assembly according to claim 1 in which said locating means comprises at least two spaced apart apertures in each of said blocks adapted to receive locating pins in the jig plate of a wire-wrap machine.

3. An assembly according to claim 1.in which said mounting members comprise channels which are dimensioned to receive said mounting guide with a clearance between all surfaces of about .015 inch.

4. An assembly according to claim 1 in which said means to engage is an angle member adapted for fastening both to the jig plate of a wire-wrap machine and the chassis of electrical equipment.

'5. An assembly according to claim 1 in Which the added tolerance of the'positioning of said terminals in said blocks and the locating means associated with each block totals less than .010 inch from a predetermined exact location.

6. An electrical Wire-wrap connector assembly comprising:

(a) a connector block having mounting guides on two opposed edges thereof;

(b) a plurality of lwire-wrap terminals mounted on said block fixedly' located relative to each other and extending from one surface of said block;

(0) means forming at least tWo aligning devices precisely located on said block relative to said pins surface for mating with locating means on the jig plate of la wire-wrap machine; and

(d) spaced elongated mounting members receiving said block between them and loosely engaging said mounting guides while leaving said block free for limited independent movement in directions parallel to said surface for mating said aligning devices with said locating means;

7. An assembly according to claim 6 including recep-j tacles for electric assemblies on a second surface of said block opposite and substantially parallel to said one surface, and a plurality of electrical assemblies plugged into said receptacles.

8. Electrical apparatus according to claim 7 in which said plurality of electrical assemblies comprises both connector plugs and circuit ca d modules.

9. Electrical apparatus according to claim 7 in which said plurality of electrical assemblies comprises circuit card modules containing monolithic circuits.

10. A method of electrical apparatus assembly using connector blocks with wire-wrap terminals comprising:

(a) incorporating first locating means in each of a plurality of connector blocks in a fixed relation to a plurality of wire-wrap terminals protruding from a first surface thereof;

(b) engaging said connector blocks loosely in mounting means permitting limited movement parallel to said surface;

(c) bringing said mounting means to a jig plate associated with a wire-wrap machine and containing second locating means for mating with said first locating means;

((1) spatially adjusting said connector blocks individually to mate said first locating means and said second locating means; and

(e) operating said wire-wrap machine to make wirewrap connections to said terminals.

11. A method according to claim 10 including the further steps of removing said mounting means from UNITED STATES PATENTS 3,008,113 11/1961 Johnson 317-101 3,042,895 7/1962 Bonhomme 339176 3,186,077 6/1965 Vickery 29--l55.5 X 3,324,443 6/1967 McFadden et a1.

FOREIGN PATENTS 809,840 4/ 1959 Great Britain.

OTHER REFERENCES Interconnection Emphasis: Flat Pack Mounting Electronic Design, vol. 12, No. 9, April 27, 1964, p. 86.

ROBERT K. SCHAEFER, Primary Examiner D. SMITH, 111., Assistant Examiner US. Cl. X.R. 

